6
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6
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15. If the wire is not driven through, disconnect from the mains power
supply, open the access cover, and tighten the drive roller clamp knob.
The drive rollers should be just tight enough to drive the wire through
to the torch, but not so tight as to prevent the drive roller from slipping
if the wire becomes blocked
16. When the wire is propelled out of the end of the torch, switch off and
disconnect from the mains power supply
17. Refit the tip and the shroud, and trim the wire so that approx 5mm
projects from the tip
Before Use
• Always wear appropriate personal protective equipment for the job that you
are to do. Use of this machine requires a welding mask, gloves, heat resistant
clothing, and if appropriate a respirator
• Always ensure that you have an appropriate fire extinguisher near to the work
area
• Always inspect your machine for damage or wear. Pay particular attention to
leads and cables. If any damage is found DO NOT USE
• Check that all casings or covers are properly closed and secured
• Position the welder in such a way that it will not move or tip in use. Ensure
that there is at least 500mm of clear space around the welder to allow proper
ventilation
Operating Instructions
WARNING:
Always unplug the welding machine from the mains supply and allow
to cool fully before attempting to fit or replace any part.
Setting the machine
• To achieve a good quality weld, the Wire Speed Dial (3), and Voltage Control
Switches (5) must be set correctly
• The two voltage control switches can be used to obtain 4 current settings:
- Lo + 1 = very low voltage suitable for thin sheet metal
- Lo + 2 = low voltage suitable for most sheet metal
- Hi + 1 = high voltage suitable for thick sheet metal
- Hi + 2 = very high voltage suitable for metal up to 5mm thick
• The wire speed should be adjusted to provide a steady arc. The correct setting
will depend on distance, current, torch speed, and other factors. Experiment
with wire speeds until you find an optimum setting.
Duty Cycle
• This machine is not designed to weld constantly. Excessive continuous welding
would cause overheating and damage to internal components
• The duty cycle defines the number of minutes, in every ten minutes, that the
machine can weld
• For a duty cycle of 10%, the machine may be used for 1 minute, and then must
be allowed 9 minutes to cool
• If the duty cycle is exceeded, the machine will automatically cut-out
• Using the machine at reduced current settings, and maintaining good ventilation
will maximise the duty cycle
Thermal cut-out
• This machine is equipped with a thermal cut-out. If the machine is overloaded,
or used beyond its duty cycle, it will automatically shut down
• Allow the machine to cool. The cut-out will automatically reset once the
machine is ready to be used
Preparing to weld
• Ensure that parts to be joined are clean, and free from rust, paint, or other
finishes
• All parts should be well supported, so that there is a gap of approximately 1mm
where you intend to form the welded joint
• Check that there are no flammable materials in the vicinity of the work area
• Attach the Earthing Clamp (7) to a cleaned area of one of the parts, as near as
practical to where the joint will be
• Ensure that there is both a responsible person and an operable fire extinguisher
at hand
• Connect the machine to the mains power supply
Welding
WARNING:
Using a welder correctly is a technical skill. A welder used incorrectly
can be highly dangerous. The information presented below is general guidance
only. If you are not entirely confident in your ability to use this tool safely DO NOT
USE.
1. Move the Power Switch (6) to the ‘ON’ position
2. Hold the torch in one hand and the face mask in the other
3. Position the torch so that the tip is approx 10mm away from the metal, at an
angle of approx 75˚
4. Hold the mask over your face, and squeeze the Trigger (2)
5. An arc should strike between the metal, and the tip. Hold the trigger for 1-2
seconds and release
6. Allow the weld to cool slightly, and move the mask away from your face. If
the settings were correct, a round 'spot' weld should have formed
7. If the weld has not fully penetrated the metal, increase the voltage setting. If
a hole has been made in the metal, reduce the voltage setting
• Practice making 'spot' welds until you are confident using the machine, and
selecting settings
• To form a 'seam' weld, hold the trigger for longer, and slowly move the torch
forward at the same time
• If the machine settings are correct, the arc should be steady, and produce a
crackling sound.
• If you hear a popping sound, or struggle to maintain the arc, adjust the wire
speed. If you feel the torch trying to 'push back' reduce the wire speed
• Creating neat, high quality, welds is a skill that takes time to master. Practice
and good preparation should result in satisfactory welds
Maintenance
WARNING:
Always unplug the welding machine from the mains supply and allow
to cool fully before attempting to fit or replace any part.
Replacing wire
1. Use a pair of pliers to draw the last of the old wire out through the tip of the
torch (if the old wire spool is not empty, cut the wire at the spool and release
the drive roller clamp knob)
2. To access the welding wire, open the Access Cover (4) on the side of the
machine
3. Remove the spool locking knob, spring and washer and the old wire spool;
slide a fresh spool of welding wire onto the spool spindle
4. Replace the washer, spring and spool locking knob, and tighten. Tighten
so that the reel of wire doesn’t unravel under its own spring tension and
resistance is felt when the spool is rotated
5. Loosen and raise the drive roller clamp knob so that the guide roller can be
swung clear
6. Carefully release the end of the wire from the spool, take care not to let the
wire unravel. Ensure that the wire tip is straight, and is cut off cleanly
7. Slowly feed the wire into the torch liner
8. Lower the drive roller clamp knob so that the guide roller is secured, and
tighten gently
9. Raise the drive roller clamp knob, and tighten gently
10. Close the Access Cover (4)
11. Pull the Shroud (1) from the torch and unscrew the tip
12. Connect the machine to the mains power supply, switch on, and hold the
torch
13. Move the torch away from the machine, so that the torch cable is straight
14. Ensure that the torch is not touching anything, and squeeze the Trigger (2).
The machine should drive the wire through to the torch
15. If the wire is not driven through, disconnect from the mains power supply,
open the access cover, and tighten the drive roller clamp knob. The drive
rollers should be just tight enough to drive the wire through to the torch, but
not so tight as to prevent the drive roller from slipping if the wire becomes
blocked
16. When the wire is propelled out of the end of the torch, switch off and
disconnect from the mains power supply
17. Replace the tip and shroud, and trim the wire so that approx 5mm projects
from the tip
NOTE:
Ensure that the tip is of the right size for the wire used.
Replacing tips
• As the welder is used, the tip may become worn. This will make the arc difficult
to control
1. To replace the tip, pull the Shroud (1) from the torch, and unscrew the old tip
2. Check that the new tip is the correct size for the wire to be used
3. Thread the new tip over the end of the wire, and screw into the torch.
Replace the Shroud (1)
Cleaning
Disconnect the machine from the mains supply before cleaning
• Keep your machine clean. Always clean dust or particles away and never allow
ventilation holes to become blocked
• Use a soft brush or dry cloth to clean the machine. If available, blow through the
ventilation holes with clean, dry, compressed air
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